Field Service Bulletin CNG Winterizing Kit ... ENP-298: CNG Winterizing Kit Instructions (Printed...
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Field Service Bulletin
CNG Winterizing Kit
Rev. A: August 16, 2017
ENP-298: CNG Winterizing Kit Instructions (Printed Copy is Not Controlled) 2 of 11
The Agility Fuel Solutions optional Winterizing Kit for CNG Agility fuel system equipped vehicles enables a way to make the low pressure CNG warm, by inserting a heat exchanger into the low pressure fuel path, as shown in Figure 1.
Figure 1. Agility Fuel Solutions Winterizing Kit system fuel flow.
Warming CNG fuel accomplishes several benefits for the natural gas engine:
a) Warmed fuel will prevent high pressure filters and fuel system components from freezing in extreme cold weather.
b) Higher CNG fuel temperature reduces the amount of hydrocarbon contaminants that turn into liquid, which can contaminate the fuel system and engine sensors.
c) The hydrocarbon contaminants remain in a gaseous state, where they can be burned in the combustion chamber.
RED = COOLANT FLOW
BLUE = FUEL FLOW
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Because these “warm fuel” benefits go beyond the prevention of frozen components, fleets in non-extreme cold weather locations may want to consider this option.
The CNG fuel warmer is a “plug and play” device installed between the pressure regulator in the fuel management module (FMM) and the low pressure filter located near the engine.
These instructions apply to CNG systems with 200xxxxx series, stand-alone FMM units. Other system configurations may also use this Winterizing Kit with some changes in layout and plumbing. Contact Agility Customer Care for more details.
Warning Statements Used in this Document
Personal injury or death may occur if procedures are not followed.
2. Affected Units
All CNG Agility Fuel Solutions vehicles in extreme cold weather locations can benefit from this extra cost accessory. This option may also be useful for non-cold weather locations.
3. Corrective Action
Does not apply.
4. Tools, Materials, Parts Needed
The Agility Fuel Solutions CNG Winterizing Kit, part number 22521014, includes:
QTY PART NUMBER DESCRIPTION
5 Ft 10401005 1-in. split loom
5 Ft 10802027 5/8-in. silicon coolant hose, blue
3 Ft 10802019 #10 JIC low pressure CNG hose, black
1 10240033 JIC -10 male to -10 female elbow
2 10240030 JIC swivel -10 female to -10 hose
5 10702049 Hose clamps
1 10702108 Hose union, 3/8-in. plastic
3 Ft 10802055 Spiral wrap
12 10702024 Cable tie
2 10240297 5/8-in. hose barb x 1/2-in. male NPT
2 10240026 JIC elbow -10 x 3/4-16 SAE
2 10700196 3/8-16 nylon lock nut, SS
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CNG Winterizing Kit, Continued
QTY PART NUMBER DESCRIPTION
2 10700193 1/4-20 nylon lock nut, SS
2 10700187 3/8-in. flat washer, SS
2 10700184 1/4-in. flat washer, SS
1 22521011 Heat exchanger bracket
1 10300981 Heat exchanger
Also required, but not included in the kit
Engine coolant, if necessary
Depressurize system before starting work. A. Close all CNG cylinder manual shutoff valves.
B. Verify the quarter turn shutoff valve on the FMM is open.
C. Start and run the engine until it stalls.
D. Remove the bottom cover of the FMM to access the bleed valve.
E. Open the bleed valve with a wrench.
F. Leave the bleed valve in the “OPEN” position.
G. All pressure gauges should read zero.
1. Depressurize the system.
2. Mount the heat exchanger and bracket near the coolant and fuel lines going in and out of the pressure regulator. The heat exchanger and bracket are designed to mount to either the left or the right side of the FMM cabinet, see Figures 2 and 3.
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Figure 2. Left: The heat exchanger should be as close to the regulator as possible. Right: The heat exchanger will be mounted to one side of the FMM box.
Figure 3. Elbows are mounted on the heat exchanger as shown.
3. Pre-plan the hose routing. Right angle fittings are mounted onto the heat exchanger and should point toward the chassis rail as shown in Figure 3.
4. Install coolant barb fittings into heat exchanger using nickel tape.
5. Install JIC fuel fittings into heat the exchanger – remember to lube O-rings before installing.
6. Make sure all elbows point toward the chassis rail as shown in Fig. 3.
7. Install bracket onto heat exchanger using new 1/4-in. nylon lock nuts and hardware. Torque to 7 ft/lbs. The heat exchanger, elbows and bracket assembly should look like Figure 4.
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Figure 4. Heat exchanger, elbows and bracket assembly ready to be mounted onto the FMM cabinet.
8. Remove the two nuts on top of the FMM and install the heat exchanger bracket, see Figures 5.
Figure 5. Left: The heat exchanger bracket mounts to the top of the FMM with existing bolts as shown. Right: A close up of the bracket and mounting bolts on top
of the FMM.
9. Refer to Figures 6 and 7: Attach coolant lines.
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Important: When routing coolant and fuel lines, make sure the coolant flows in the opposite direction of the low pressure fuel. See Figure 1 for coolant and fuel flow direction.
a. Working under the FMM, clamp off the two coolant hoses going into the regulator to minimize coolant loss.
b. Verify which coolant hose is the return line from the engine block (water pump inlet) and remove it from the regulator.
c. Attach a union to the return hose end.
d. Extend the return line with a 20-in. piece of blue coolant hose connected to the union. Use a hose clamp to secure the hose.
e. Attach the return hose to the outside coolant barb on the heat exchanger with a hose clamp.
f. Attach a new 30-in. piece of coolant hose to the regulator and to the inside coolant barb on the heat exchanger, and tighten the hose clamp.
Figure 6. Coolant lines should be protected with insulating sleeve.
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Figure 7. For reference: Heat exchanger ports are “Inside” when they are closest to the chassis rail, and “outside” when they are near the outside of the vehicle.
10. Refer to Figures 8 to 10: Install low pressure fuel lines.
a. Remove the low pressure fuel line from the regulator and attach it to the JIC elbow on the heat exchanger. A second elbow (included in the kit) may be needed to help hose routing, see Figure 8.
b. Attach one end of a 34-in. length of fuel hose to the regulator and other end to the outside JIC fitting on heat exchanger.
Figure 8. A second JIC elbow may be needed to help hose routing.
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Figure 9. Fuel lines installed on the heat exchanger.
Figure 10. Fuel lines installed on the heat exchanger from another angle.
11. Verify all fittings and hose clamps are tight.
12. Remove coolant line clamps.
13. Purge all air out of the cooling system and top off engine coolant by following the OEM vehicle/chassis instructions.
14. Repressurize the system
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a. Tighten the bleed valve in the FMM
b. Slowly turn on manual tank valves
c. Open the 1/4-turn shutoff valve
15. Pressure check all newly installed parts by turning the ignition key to the on position to allow fuel flow to the engine and the new heat exchanger.
16. Check for fuel leaks using approved gas detection fluids and electronic snoopers.
17. If any leaks are found, depressurize the system and fix them.
18. Check for engine coolant system leaks, and fix as necessary.
19. If everything is leak-free, the installation is complete.
Figure 11. The completed installation should look like this. As a final step, secure hoses with proper clamps and tie-down devices.
2. Warranty Information
Note: This optional modification is covered by our standard warranty: 12 months. Standard repair time (SRT) is 2.5 hours. If you have any questions, contact Agility Fuel Solutions Customer Care: +1 949 267 7745, toll free: +1 855 500 2445 or firstname.lastname@example.org.
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The information provided within this document is proprietary and confidential. All prior versions, including updates and revisions forwarded separately, are proprietary. The information provided by Agility Fuel Solutions to its customers and clients is solely for the use of those customers and clients